Dynamic Irradiation Overlap Control for Homogeneous 3D Workpieces
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Solution Overview
Problem
The use of multiple irradiation units in additive manufacturing can lead to inhomogeneities in the workpiece structure, resulting in quality defects.
Innovation Solution
A method and device utilizing at least three irradiation units with overlapping irradiation regions, allowing flexible selection and variation of irradiation units for each layer, and varying the position and boundaries of the overlap region to improve homogeneity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple irradiation units are used to irradiate a raw material powder layer in parallel, then manufacturing time is reduced, but inhomogeneities in the workpiece structure occur resulting in quality defects
Solution Approach 1:
The patent implements dynamic selection of irradiation units for each layer by varying the overlap region position and boundaries between successive layers. This dynamic adjustment ensures that different portions of the workpiece are irradiated by different units, distributing the inhomogeneity effects across the entire workpiece rather than concentrating them in specific regions, thereby maintaining overall structural homogeneity while achieving parallel processing speedups
Solution Approach 2:
The patent applies local quality by creating position-dependent irradiation assignments where specific irradiation units are selected for specific regions (overlap regions) of the workpiece based on their irradiation capabilities and characteristics. This allows optimization of local irradiation quality while maintaining global productivity through parallel processing
2Productivity
If multiple irradiation units are used to irradiate a raw material powder layer in parallel, then manufacturing time is reduced, but imprecise transitions between irradiation regions occur
Solution Approach 1:
The patent dynamically adjusts the boundaries and position of overlap regions between successive workpiece layers. By varying which irradiation units handle the overlap regions in different layers, the system prevents fixed transition errors from repeating at the same locations, thereby improving overall transition precision across the entire workpiece while maintaining parallel processing efficiency
Solution Approach 2:
The patent implements periodic variation in the assignment of irradiation units to overlap regions across successive layers. This periodic redistribution ensures that transition precision issues are distributed and averaged out across the workpiece, preventing localized defects while maintaining the productivity benefits of parallel irradiation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces manufacturing time while enhancing the quality and homogeneity of the manufactured workpieces by minimizing inhomogeneities and imprecise transitions.
Implementation Method 1
Irradiation can take place by means of electromagnetic radiation, for example in the form of laser radiation
Implementation Method 2
The laser radiation penetrates the raw material powder material and solidifies it, for example as a result of heating, which causes fusion or sintering
Data Source
AI summary
The invention relates to a method for controlling an irradiation system (20), the irradiation system (20) being used in a device (10) for the additive manufacturing of three-dimensional workpieces and comprising at least three irradiation units (22a-d, 50), the method comprising the following steps: a) defining an irradiation region (30a-d) for each of the irradiation units (22a-d, 50), the irradiation regions (30a-d) each comprising a portion of an irradiation plane (28) which extends parallel to a carrier (16) of the device (10), and the irradiation regions (30a-d) being defined such that they overlap in a common overlap region (34); b) irradiating a raw material powder layer on the carrier (16) to produce a workpiece layer; c) arranging a further raw material powder layer on the already jetted raw material powder layer to produce a further workpiece layer. d) The invention also relates to a device for performing this method.